CN102985212B - The hot input control of welding system - Google Patents

The hot input control of welding system Download PDF

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Publication number
CN102985212B
CN102985212B CN201180034363.1A CN201180034363A CN102985212B CN 102985212 B CN102985212 B CN 102985212B CN 201180034363 A CN201180034363 A CN 201180034363A CN 102985212 B CN102985212 B CN 102985212B
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China
Prior art keywords
welding
variable
level
current
source
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Chinese (zh)
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CN102985212A (en
Inventor
肯尼斯·艾伦·费舍尔
詹姆斯·F·乌尔里奇
瑞安·杰罗姆·林德曼
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Illinois Tool Works Inc
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Illinois Tool Works Inc
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/10Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1006Power supply
    • B23K9/1043Power supply characterised by the electric circuit
    • B23K9/1056Power supply characterised by the electric circuit by using digital means
    • B23K9/1062Power supply characterised by the electric circuit by using digital means with computing means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/095Monitoring or automatic control of welding parameters
    • B23K9/0953Monitoring or automatic control of welding parameters using computing means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/18Submerged-arc welding
    • B23K9/186Submerged-arc welding making use of a consumable electrodes

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Arc Welding In General (AREA)
  • Arc Welding Control (AREA)

Abstract

The hot input control method of a kind of welding system comprises data reception step, and the data that this step receives to be encoded obtained data to the hot input value hot input range of expection be between the upper limit and lower limit.Described method also comprises data reception step, and the data that this step receives change to the expection of the first welding variable level in a bond pads variable obtained data of encoding.In addition, described method also comprises the change of the second welding variable level determined in a bond pads variable.The determined change of second welding variable level is applicable to maintain heat in welding operation and inputs in the hot input range of expection.

Description

The hot input control of welding system
The cross reference of related application
That subject application requires to submit on July 13rd, 2011, application number is 13/182,353, denomination of invention is that the U.S. Patent application of " the hot input control of welding system " and on July 14th, 2010 submit to, application number is 61/364,257, denomination of invention is the priority of the U.S. Provisional Patent Application of " control of subarc welding system ", and these two applications are incorporated to herein all by reference.
Background technology
The present invention relates generally to welding system, particularly relates to hot input control system and the method for welding system.
Welding procedure is universal in all trades and professions, and is applicable to various application.Such as, welding procedure is through being commonly used for following application: as shipbuilding, industrial building and maintenance etc.In this welding procedure, operating personnel use various control appliance to control one or more parameters of welding operation usually.Such as, outfit can be used as the foot-operated of user interface and changes welding procedure electric current, voltage or any other call parameter with manual overvide to make operator.Traditionally, operating personnel attempt optimize welding performance time, change one or more welding variable by suitable interface and observation variable change on welding impact.But the heat that the change of these welding variablees may cause per unit distance to be delivered to weld seam usually changes, thus affects the mechanical performance of weld seam, and welder may be difficult to identify these affected mechanical performances.Therefore, welding system need be improved to overcome this defect.
Summary of the invention
As described below, welding system comprises the source of welding current with power-switching circuit, and power-switching circuit produces the source of welding current being applicable to welding operation and exports.The source of welding current can be used for the hot input level received needed for welding operation and the expection change of welding variable level.Described welding system also comprises the control circuit be communicatively connected on the source of welding current, this control circuit is suitable for the expection received required hot input level and welding variable level and changes obtained data of encoding, to determine the second welding variable level being suitable for substantially maintaining required hot input level, and produce control signal to control the fixed second welding variable level of source of welding current execution.
As described below, one method comprises data reception step, the data that this step receives to be encoded obtained data to the hot input value hot input range of expection be between the upper limit and lower limit, also can comprise data reception step, the data that this step receives change to the expection of the first welding variable level in a bond pads variable obtained data of encoding.Described method also comprises the change of the second welding variable level determined in a bond pads variable.The determined change of second welding variable level is applicable to maintain heat in welding operation and inputs in the hot input range of expection.
As described further, welding system comprises the source of welding current with power-switching circuit and operator interface, power-switching circuit produces the source of welding current being applicable to welding operation and exports, the adjustment that operator interface carries out the welding variable in a bond pads variable for receiving required hot input level and operator.Described welding system also comprises the wire feeder be connected on the source of welding current, and it applies the source of welding current and exports on the welding wire of institute's feeding.Described welding system also comprises navigation system, relative to each other locates for making welding gun and workpiece.Described embodiment also comprises control circuit, for receiving, the adjustment of required hot input level and welding variable is encoded obtained data, to determine the change of the second welding variable level in a bond pads variable, this change makes the input of welding operation heat substantially equal required hot input level, and produces control signal with the determined change of the second welding variable of encoding.The control signal produced is passed in the source of welding current, wire feeder, navigation system or their combination, for welding operation.
Accompanying drawing explanation
Read following specific embodiment with reference to accompanying drawing and be conducive to understanding better these and other feature, aspect and advantage of the present invention, wherein in accompanying drawing, identical characters represents same parts:
Fig. 1 is the functional unit figure with the exemplary submerged-arc welding system of hot input control performance according to the embodiment of the present invention;
Fig. 2 is the flow chart of the illustrative methods for adjusting heat input in welding operation according to the embodiment of the present invention;
The flow chart of Fig. 3 shows the embodiment of method in Fig. 2, and it is for adjusting the heat input in constant current welding operation; And
The flow chart of Fig. 4 shows the embodiment method that can be used for adjusting workpiece temperature in welding operation.
Detailed description of the invention
As detailed below; this feature of embodiment of welding system for the input of weld seam heat can be controlled during workpiece welding operation described herein can be conducive to automatically or semiautomatic welding welding system (as submerged-arc welding system; wherein protect/isolate weld zone by graininess solder flux), wherein can change the various welding variable levels in whole welding operation.In such systems, during the instruction change first welding variable level manually or automatically produced, the embodiment provided can change another welding variable to maintain the heat input of per unit distance within desired level or default value scope.For this reason, some embodiment of disclosed welding system can produce control signal, and coding welding variable change, as voltage, electric current, wire feed rate, and/or gait of march and dependent variable thereof.These control signals can be delivered in welding system equipment, as the source of welding current, wire feeder and/or navigation system, and then the input of adjustment weld seam heat.
Now forward accompanying drawing to, the exemplary submerged-arc welding system 10 of Fig. 1 Power supply, control and supply needed for welding operation.But although it should be noted that embodiment described herein is the embodiment of submerged-arc welding system, these embodiments are still compatible well with the welding system of other types.Such as; the heat input adjustment control that the present invention discloses is applicable to any wire feed technique; as gas-operated (gas metal arc welding (GMAW)) or without gas operation (protection metal arc welding (SMAW)), or any welding operation not comprising wire feed technique.Further, the embodiment that the present invention discloses can be used for Metallic Inert Gas (MIG) welding, tungsten inert gas (TIG) welding, or welding rod welding.
Described welding system 10 comprises the source of welding current 12 with operator interface 14.In manual or semi-automatic operation, described operator interface 14 can comprise control panel, controls the welding material supplying welding gun, as gas flow, wire feed etc. for welder.For this reason, in certain embodiments, described operator interface 14 can comprise input or interface equipment, and as knob or switch, wherein said operating personnel can use this knob or switch adjustment welding parameter (as voltage, electric current etc.).The welding variable controlling the operation of the described source of welding current 12 can comprise voltage, electric current, wire feed rate and gait of march.Such as, voltage can be changed to control shape and the outward appearance in welding bead cross section by automatic or manual.Equally, adjustable current intensity and wire feed rate are to control welding bead length of penetration, mother metal dilution situation etc.Equally, gait of march can be adjusted to control welding bead permeability and size by automatic or manual.Further, discussed in more detail below, these or other welding parameter can be adjusted input on desired level or within required scope with the heat maintaining per unit distance in whole welding operation.In addition, it should be noted that those skilled in the art can use the method disclosed in suitable method and the present invention to calculate the heat input of per unit distance.Such as, by integrated voltage and current production and divided by gait of march calculate per unit distance heat input.
As shown in the figure, described welding system 10 also comprises wire feeder 16, and it provides welding wire for welding operation for welding gun.In certain embodiments, described wire feeder 16 also comprises operator interface 18, helps user to arrange one or more wire feed parameter, as wire feed rate.But, in other embodiments, described operator interface 18 can be omitted, and user inputs than class parameter by the operator interface 14 in the described source of welding current 12.In the illustrated embodiment, connect the described source of welding current 12 to described wire feeder 16 by a branch of cable 20, and supply welding material for welding operation.This wire harness 20 comprises power line 22 and control cables 24.It should be noted that in certain embodiments, wire harness 20 described in unbundling.
Other intrawares of the described source of welding current 12 and wire feeder 16 as shown in Figure 1.Once the operator interface 14 illustrated receives the selection of setting, hot input level as required or scope, these welding are arranged on the control circuit 26 that can be passed in the described source of welding current 12.Described control circuit 26 runs and controls the bonding power be applied on the welding wire for performing required welding operation and exports.For this reason, described control circuit 26 is connected on power-switching circuit 28.Described power-switching circuit 28 in order to produce finally be applied to contact tube 32 welding wire 30 on power output.Various power-switching circuit can be used, comprise chopper, booster circuit, reduction voltage circuit, inverter, converter etc.The structure of this circuit may be type known in the field.Such as, connect the power supply 34 in described power-switching circuit 28 to electrical network, although other power supplys can be used, as engine-driven generator, battery, fuel cell or other alternate source.
In certain embodiments, be provided with described control circuit 26 and encode obtained data to required hot input level or scope to receive, wherein operating personnel specify required hot input level or scope by described operator interface 14.Further, described control circuit 26 also can receive to welding variable level (as weldingvoltage or electric current) required change encode the data that obtain.Once receive required change, described control circuit can calculate the expection change of heat input according to required change.Further, described control circuit can determine the suitable change of another welding variable, and when performing expection change, this variable can keep heat input on desired level or in required scope.Such as, in an embodiment of the present invention, the expection heat input of per unit distance is about 25kJ/cm, and in weld seam process of rework, indicated by operating personnel/and the expection change of needs can be electric current to be increased, and wherein this electric current increase can realize required filling rate.In the case, described control circuit 26 can determine the impact that the curent change of indicated/needs inputs heat, and adjustable gait of march is to offset this impact, thus keeps heat input on desired level.Above feature describes in detail, sees the description to Fig. 2 and 3.
Finally, as shown in Figure 1, the described source of welding current 12 also comprises interface circuit 36, exchanges signal in order to described control circuit 26 with described wire feeder 16.Described wire feeder 16 also comprises interface circuit 38, and this interface circuit connects the interface circuit 36 in described power supply 12 by data cable 24.In certain embodiments, the assembly run between described interface circuit and multicore cable can be provided with many pins interface, to allow, as the information of wire feed rate, technique, selected electric current, voltage or power water equality, at described power supply 12, wire feeder 16 or arrange on both.
Described wire feeder 16 also comprises the control circuit 40 be connected on interface circuit 38.Described control circuit 40 can control wire feed rate by the selection of operating personnel, and by described interface circuit 38, these settings is fed back to power supply 12.To select one or more welding parameter on the operator interface 18 that described control circuit 40 is connected to wire feeder 16 further, especially wire feed rate.In addition, in certain embodiments, described operator interface 18 is used also can to select this type of welding parameter, as technique, wire types used, electric current, voltage or power setting etc.In addition, it should be noted that, can be provided with described control circuit 40 in certain embodiments to adjust the heat input in welding operation, this welding operation can be coordinate/pull together the welding operation run or the welding operation run independent of the control circuit 26 in the source of welding current 12 with the control circuit 26 in the source of welding current 12.Further, should also be noted that the control circuit that can adjust heat input in welding operation may be positioned at the source of welding current 12, wire feeder 16, or in any other desired location.Such as, in certain embodiments, described control circuit may be arranged in separate unit, or is integrated in other system assembly, as navigation system 48.Really, the position of the control circuit 26 in the described source of welding current 12 does not also mean that the position limitation of described control circuit on this position.
Under the control of control circuit 40, described wire feeder 16 also comprises the assembly to described contact tube 32 and welding application feeding welding wire.Such as, the bobbin 42 of one or more welding wire 30 is housed in described wire feeder 16.Release welding wire 30 from described bobbin 42, and be progressively fed on described contact tube 32.Be provided with feeding motor 44, tend to described contact tube 32 to engage with feeding roller bearing 46 and to promote welding wire from wire feeder.In practice, a roller bearing of described roller bearing 46 is mechanically connected on described motor 44, and by described motor, roller bearing being rotated with the welding wire driven from wire feeder, the roller bearing simultaneously matched is biased to keep two good contacts between roller bearing and welding wire towards welding wire.Some systems may comprise the roller bearing of this type multiple.
Usually, by described welding cable 22, the electric power of described power supply 12 is guided on described welding wire 30 in a conventional manner.Equally, in gas welding embodiment, by described wire feeder and welding cable feeding protective gas.In welding operation, described welding wire is pushed into by described welding cable sheath and tends to described contact tube 32.In described contact tube, be provided with extra traction electric machine and associated drives roller bearing can be furnished with, to its adjustment to provide required wire feed rate.When described welding wire is pushed into trend described contact tube 32, navigation system 48 move described contact tube 32 or described workpiece 50 and in whole welding operation relative to described workpiece 50 to locate described contact tube 32.Such as, in the illustrated embodiment, along with the carrying out of described welding operation, described navigation system moves described contact tube 32 along the direction of arrow 52.
Flux hopper 54 provides graininess welding flux layer 56 on described workpiece 50.Along with described contact tube 32 moves along direction 52, solidified welding material 58 and solidification solder flux 60 are formed.Flux restoring system 62 reclaims unfused solder flux and reuses for welding operation afterwards.In addition, in the illustrated embodiment, temperature sensor 64 is monitored the temperature of described workpiece 50 and by cable 66, measured value is passed to described control circuit 26.Further, work attachment 68 connects on described workpiece 50 to the described source of welding current 12 with closed described power supply 12, circuit between contact tube 32 and workpiece 50.
Fig. 2, for laying respectively at the embodiment of the method 70 performed by the control circuit 26 or 40 in power supply 12 or wire feeder 16, inputs with the heat adjusted in welding operation in per unit distance.Described method 70 comprises startup welding operation (square frame 72), such as: when activating welding system.Described method 70 also comprises hot input level needed for reception or scope (square frame 74).Such as, operating personnel can specify required hot input value or have the required hot input value of tolerance.
Progressive ground, described method 70 comprises reception instruction, and this instruction is for changing the level (square frame 76) of the welding variable in a bond pads variable.Such as, a described bond pads variable may comprise weldingvoltage, welding current, wire feed rate, gait of march or their combination, and this instruction can relate to the change needed for arbitrary variable.Once receive required change, control signal can produce and require to change another welding variable in a described bond pads variable and change (square frame 78) with the expection of offsetting the relevant heat of the change needed for welding in variable with first and inputting.As long as automatic or manual adjusts described welding variable, can repeatedly repeat this step in whole welding operation.
Fig. 3 shows method 80, and it is the embodiment of method 70 in Fig. 2.Such as, in this embodiment, the operator scheme that controller uses is constant-current mode.Therefore, once start welding operation (square frame 72) and specify needed for hot input level or scope (square frame 74), by operation interface receive from operator instruction with to welding voltage levvl carry out required change (square frame 82).Under described controller is in constant current operation pattern, under therefore generation instruction makes welding current remain on preset level (square frame 84).But, in order to offset the expection change of heat input according to the change of required voltage levvl, produce instruction to change gait of march (square frame 86).Like this, in whole welding operation, described heat input can maintain in required level or in required scope, and under described electric current can maintain constant level substantially.
It should be noted that in other embodiments, similar control method can be used for constant voltage operator scheme or constant power operation pattern.Such as, in constant voltage embodiment, after the change of operating personnel's specified current flow level, instruction can produce to keep voltage under preset level.But, in order to offset the expection change of heat input according to levels of current change, may need to adjust described gait of march.In addition, if operating personnel specify the expection of gait of march to change, Modulating Power level is carried out to offset expection heat input change by adjusting voltage or electric current or both.Further, in the multi sphere system comprising multiple welding machine, the voltage of the one or more welding machine of adjustable and/or electric current are to offset expection heat input change.
Fig. 4 is the embodiment of the method 88 that can be used for welding controller, to adjust workpiece temperature in required level or within required scope.Once start welding operation (square frame 72), and receive the temperature (square frame 90) that workpiece is detected, the temperature be detected relatively and preset required scope to determine the temperature that is detected whether in predetermined tolerance (square frame 92).When described temperature is in predetermined tolerance, whether the described temperature of continuous or periodic monitoring there is any change.But when described temperature is not in predetermined tolerance, the generation by control signal changes the heat input of per unit distance, this control signal is the control signal (square frame 94) that the welding variable of requirement impact heat input carries out changing.That is, in the present embodiment, one or more welding variable can be changed as requested to adjust heat input change, thus affect workpiece temperature until the temperature be detected falls in preset range.
Although only illustrate and describe some feature of the present invention, but those skilled in the art can carry out various distortion and change herein.Therefore, be understandable that, appended claims is intended to comprise and falls into distortion in connotation of the present invention and change.

Claims (20)

1. a welding system, comprising:
Be provided with the source of welding current of power-switching circuit, described power-switching circuit is set to produce weld power and exports for welding operation, and the wherein said source of welding current is set to receive the adjustment that the first welding variable level to the first welding variable in a bond pads variable carries out for the hot input level needed for welding operation and operator; And
Be communicatively connected to the control circuit on the source of welding current, this control circuit to be encoded obtained data to required hot input level and described first welding variable level for receiving, determine the change of the second welding variable level of the second welding variable being suitable for the described bond pads variable substantially maintaining required hot input level, and produce control signal to control the described second welding variable level of source of welding current execution.
2. welding system according to claim 1, wherein said first welding variable level comprises voltage levvl, and the second welding variable level comprises gait of march size.
3. welding system according to claim 1, wherein said first welding variable level comprises levels of current, and the second welding variable level comprises voltage levvl.
4. welding system according to claim 1, comprises with the wire feeder of required speed to welding gun feeding welding wire, and wherein the second welding variable level is the wire feed rate being sent to wire feeder by the source of welding current.
5. welding system according to claim 1, wherein required hot input level comprises a series of hot input value suitable in pre-set tolerance frame.
6. welding system according to claim 1, wherein the source of welding current comprises constant current source or constant voltage source operates for submerged-arc welding.
7. welding system according to claim 6, comprises flux hopper, for supplying solder flux to welding operation, and flux restoring system, for reclaiming unfused solder flux from workpiece.
8. a welding method, comprising:
Receive the first data, described first data are obtained data of encoding to the hot input range of expectation comprising the hot input value be between the upper limit and lower limit;
Receive the second data, described second data are obtained data of encoding to the expectancy changes of the first welding variable level in a bond pads variable; And
Determine the change of the second welding variable level in a described bond pads variable, wherein the change of determined second welding variable level is suitable for hot in maintenance welding operation input in desired hot input range.
9. welding method according to claim 8, a wherein said bond pads variable comprises weldingvoltage, welding current, wire feed rate, gait of march or their combination.
10. welding method according to claim 8, wherein the first welding variable comprises weldingvoltage, and the second welding variable comprises wire feed rate.
11. welding methods according to claim 8, comprise and the change of determined second welding variable level being sent in the source of welding current, solder wire convey device, navigation system or their combination.
12. welding methods according to claim 8, wherein said welding operation is the submerged-arc welding operation performed by constant current or the constant voltage source of welding current.
13. welding methods according to claim 8, wherein the first welding variable comprises weldingvoltage, and the second welding variable comprises gait of march.
14. 1 kinds of welding systems, comprising:
There is the source of welding current of power-switching circuit and operator interface, described power-switching circuit is set to produce the weld power being applicable to welding operation and exports, the adjustment that operator interface carries out the first welding variable in a bond pads variable for receiving required hot input level and operator;
Wire feeder, to be connected on the source of welding current and to provide weld power to export to supplied welding wire;
Navigation system, relative to each other locates for making welding gun and workpiece; And
Control circuit, for receiving, obtained data of encoding are adjusted to required hot input level and the first welding variable, determine the change of the second welding variable level in a described bond pads variable, this change is suitable for keeping the input of welding operation heat to be approximately equal to required hot input level, and produce control signal with the change of determined second welding variable of encoding, wherein produced control signal is sent in the source of welding current, wire feeder, navigation system or their combination, for performing in welding operation.
15. welding systems according to claim 14, a wherein said bond pads variable comprises weldingvoltage, welding current, wire feed rate, gait of march or their combination.
16. welding systems according to claim 14, wherein said welding operation is submerged-arc welding operation, and the source of welding current can operate under constant current or constant-voltage mode.
17. welding systems according to claim 16, comprise flux hopper, it supplies solder flux to welding operation, also comprises flux restoring system, and it reclaims unfused solder flux from workpiece.
18. welding systems according to claim 14, wherein required hot input level comprises a series of hot input value suitable in pre-set tolerance frame.
19. welding systems according to claim 14, wherein wire feeder comprises the motor be connected on one group of driving roller bearing, for releasing supplied welding wire from supply bobbin.
20. welding systems according to claim 14, wherein said first welding variable comprises weldingvoltage, and described second welding variable comprises wire feed rate.
CN201180034363.1A 2010-07-14 2011-07-14 The hot input control of welding system Expired - Fee Related CN102985212B (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US36425710P 2010-07-14 2010-07-14
US61/364,257 2010-07-14
US13/182,353 2011-07-13
US13/182,353 US10766089B2 (en) 2010-07-14 2011-07-13 Heat input control for welding systems
PCT/US2011/044054 WO2012009563A1 (en) 2010-07-14 2011-07-14 Heat input control for welding systems

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CN102985212B true CN102985212B (en) 2015-09-02

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BR (1) BR112013000816A2 (en)
PL (1) PL2593264T3 (en)
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WO (1) WO2012009563A1 (en)

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WO2012009563A1 (en) 2012-01-19
PL2593264T3 (en) 2016-02-29
EP2593264B1 (en) 2015-09-02
EP2593264A1 (en) 2013-05-22
US10766089B2 (en) 2020-09-08
RU2555308C2 (en) 2015-07-10
BR112013000816A2 (en) 2016-05-24
CN102985212A (en) 2013-03-20
US20120012559A1 (en) 2012-01-19
EP2593264B2 (en) 2018-11-14
RU2013106263A (en) 2014-08-20

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